Phenix 635-5P User manual
PORTABLE AC DIELECTRIC TEST SET
Model Number 635-5P
LO/ch
October 17, 1997 +
TABLE OF CONTENTS
Section Number
DANGER
TECHNICAL SPECIFICATIONS 1
INTRODUCTION 2
SAFETY 3
CONTROLS AND INSTRUMENTATION / FIGURE 1 4
SET-UP AND OPERATION 5
ELECTRICAL SCHEMATICS 6
PARTS LIST 7
MAINTENANCE 8
WARRANTY 9
RETURNED MATERIAL 10
PARTS ORDERING INFORMATION 11
RECOMMENDED SPARE PARTS 12
1-1
TECHNICAL SPECIFICATIONS
INPUT: 120 VAC, 2 A, 1 phase, 60 Hz
OUTPUT: 0-35,000 VAC
Due to the short circuit current limiting of the 635-5P, the following maximum full
output voltages are available at the specified currents.
Output Current Approx. Max. Voltage Available
1 mA 32 kV
2 mA 27 kV
3 mA 24 kV
4 mA 20 kV
5 mA 15 kV
6 mA 10 kV
Current limited to <10 mA output on short circuit.
INSTRUMENTATION:
Voltmeter: 3 1/2 digit LCD display
Scale: 0-35.0 kVAC
Accuracy: +/-1% FS
Currentmeter: 3 1/2 digit LCD display
Scale: 0-10.0 mA AC
Accuracy: +/-1% FS
DIMENSIONS: 18.5" H x 13.5" W x 11" D; 66 lbs.
(470 mm H x 343 mm W x 279 mm D; 30 kg)
2-1
INTRODUCTION
The Phenix Model 635-5P is a portable AC Dielectric Test Set for performing dielectric strength
tests primarily on vacuum bottles. The test set may also be used for testing other samples which
are no load or light load (< 1 mA) in nature. A built-in self-protection feature current limits the
short circuit output current to safe levels, preventing damage to the test set. Under dead short
conditions, the output voltage will drop to zero.
3-1
SAFETY
Because the 635-5P is designed to supply high voltages, safeguards have been built into it.
These safeguards are only effective if safe work practices are also used. The test set and these
procedures have been designed for use by knowledgeable electrical workers who have been
properly trained in its use.
Please note the following:
1. The test set must be grounded. The third prong on the input power plug is for this purpose.
DO NOT REMOVE THIS PRONG.
2. The tests described here are to be used ONLY on DE-ENERGIZED and isolated
transformers.
3. HIGH VOLTAGES (LETHAL IN VALUE) ARE GENERATED DURING THE TESTS AND
EXTREME CAUTION MUST BE USED. FOLLOW ALL SAFETY PROCEDURES.
GROUND OBJECT UNDER TEST BEFORE TOUCHING.
4. High Voltage section is located in a plastic case. DO NOT touch case while high voltage is
energized. Do not touch high voltage output lead when high voltage is energized.
5. Maintain safe working distances when the test set is energized.
4-1
CONTROLS AND INSTRUMENTATION
The following is a brief description of the various controls and instrumentation found on the Model
635-5P.
Refer to Figure 1.
1. Main Power On Switch. Toggle switch supplies power to test set.
2. ON Indicator Lamp. Neon lamp indicates Main Power is ON.
3. Fuse. Overload protection for all control, metering, and power circuits.
4. High Voltage ON. "Deadman" pushbutton must be depressed and held to energize high
voltage. Pushbutton will light when high voltage is energized. Failure to hold down
pushbutton will cause high voltage to de-energize. Pushbutton is zero start interlocked.
5. Fault Indicator Lamp. Neon indicator lamp will glow or flicker indicating breakdown or
arcing within the object under test.
6. Voltage Adjust Knob. Controls output voltage from zero to full output voltage. Knob
must be in the zero or full counter clockwise position to energize high voltage.
7. Output Kilovoltmeter. Digital LCD display indicates output voltage. Scale: 0-35.0 KVAC.
8. Output Currentmeter. Digital LCD display indicates output current. Scale: 0-10.0 mAAC.
5-1
SET-UP AND OPERATION
1. Place unit on bench or other suitable flat surface.
2. Undo (2) latches on side of case.
3. Remove cover, power, control, return, and output cables. Exercise caution in removing cover
because control cables are permanently connected to the bottom of the case.
4. Separate High Voltage (bottom) section and control (cover) section to provide safe operating
distance between operator and high voltage.
5. Locate red high voltage output lead. Insert banana jack end of lead into jack provided on top
of high voltage section.
6. Connect high voltage and low voltage return leads to object under test.
7. Connect input power cord to a 117 VAC, 60 Hz grounded outlet.
8. Turn on Main Power toggle switch. Main Power indicator lamp should glow. Digital output
meters should now display zeros (+/-1 count).
9. Turn output voltage control knob to zero (full counter clockwise position). Depress high
voltage on pushbutton. Button should now glow indicating high voltage is energized. Raise
output voltage to desired test level by turning voltage control knob clockwise.
While raising the output voltage, pay special attention to the output currentmeter. If it should
suddenly show a high reading, this means the sample has broken down. Arcing or temporary
breakdowns will be indicated by the fault lamp.
10. At completion of high voltage test, return voltage control knob to zero and release high voltage
on pushbutton. High voltage on lamp should go out. If high voltage on pushbutton is released
while voltage control knob is off of zero, high voltage will deenergize and cannot be renergized
until voltage control knob is returned to zero.
11. To repack unit for transport, reverse step 3 above. Be sure to remove high voltage lead from
jack on top of high voltage section. Failure to do so may scratch or damage control panel.
A Note About Automatic Current Limit Circuit:
Unit is equipped with automatic current limit circuit which limits maximum output current to
approximately 10 milliamperes under dead short conditions. This feature consists of a high
impedance high voltage transformer combined with a series connected primary resistance to limit
the maximum current. This circuit will allow you to attain maximum output voltage when unit is
lightly loaded (less than 1 milliampere) while protecting the unit from damage when shorts or
breakdowns occur in the object under test.
6-1
ELECTRICAL SCHEMATICS
Drawing Number Description
1. -01-E634 Model 635-5P Portable AC Dielectric
2. -01-P118 Dual 5 VDC Power Supply PC Board
3. -01-P119 Meter Calibration PC Board
7-1
PARTS LIST
ITEM DESCRIPTION PART NO.
A1 PCB1165 Dual 5VDC Power Supply 31116500
A2 PCB1166 Meter Cal Board 31116600
BDG1 Diode Bridge 1789210
C1 Capacitor, .22µfd, 400V 1093170
C2 Capacitor, .01µf, 1kV 1092050
F1 Fuse, 5A, 250V, 3AG 1603605
Relay Socket, 3 Pole 1157620
J1 Corcom Connector 1152590
J2 10 Pin Female Recept. 1150128
J2 10 Pin Male Plug 1150129
Clamp 1150926
K1 Relay, 3PDT, 115VAC 1700610
M1-2 Meter, Acculex DP652 1506400
PL1,3 Lamp, Neon 115VAC 1423260
R1 Resistor, 2.7K Ohm, 2W 1712085
R2, A&B Resistor, 50 Ohm, 200W 1740208
Resistor, 500 Ohm, 50W 1741030
R3 Resistor, 10 Ohm, 2W 1710155
R4-2pcs. Resistor, 75M Ohm, 6W 1748200
R5 Resistor, 2K Ohm, 1/2W 1722078
R6 Resistor, 5K, 1/2W 1712110
R7 Resistor, 1.2M Ohm, 1/2W 1715996
S1 Switch, Toggle, DPDT 1865005
S2, PL2 Switch, Pushbutton, EAO 1860120
Lamp, 60V 1420150
Lens, Red 1422150
SCR1 SCR, C106D 1803100
SG1 Spark Gap, 90V 1605110
T1 Variac, Staco 221 1890105
T2 Transformer, HV, Phenix GV1118 38321118
Z1,2 5.6V Zener 1780034
Miscellaneous Components
Line Cord, 18/3, 8 ft. long 1077167
Case, Anvil 16”H x 9 ½”Dx 12”W 2100525
Return Lead, #10AWG, Hypalon 1078170
Clip #27C 1353042
Boot, Black 1353041
High Voltage Lead --
Clip #27C 1353042
Boot, Red #29 1353040
Plug, Banana, Red 1356200
Interconnect Cable, 4 Cond, 20AWG (2 pcs.) 1075040
8-1
MAINTENANCE
No solution or chemical stronger than ordinary mild soap and water solution should be applied to
the cabinet area of this unit. Care must be used when cleaning the meter faces and console
panel. Abrasives may remove printing and descriptive titles and scratch meter faces. When
cleaning, always have unit disconnected from power source. Never attempt to clean inside the
unit as the cleaning solution may cause damage to the electronic components.
In the event it becomes necessary to replace any parts, a complete description can be found with
the supplied parts list.
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